USP 671: Why Package Performance Testing Matters for Pharmaceutical Products

Explore transmission limits, testing methods, and how light-resistant packaging helps safeguard photosensitive drug products.

The pharmaceutical industry is entering a new era of regulatory scrutiny when it come to plastic packaging systems used for drug products . With the implementation of USP <661.1> and <661.2> , pharmaceutical companies must demonstrate that their packaging materials and systems are suitable for their intended use and do not compromise product quality or patient safety. In practice, regulatory authorities such as the FDA now expect companies to demonstrate compliance with USP <661.2> when qualifying plastic packaging systems used with drug products. What Is USP <661.2> USP <661.2>, titled "Plastic Packaging Systems for Pharmaceutical Use," establishes requirements for evaluating plastic packaging systems that contain pharmaceutical products. These packaging systems include bottles, containers, closures, unit dose packages and other components that come into direct contact with the drug product. The chapter focuses on ensuring that packaging systems are chemically suitable and safe for drug storage and administration . Unlike USP <661.1> which evaluates the materials of construction , USP <661.2> evaluates the entire packaging system and its interaction with the drug product. FDA Expectations and Regulatory Requirements The U.S. Food and Drug Administration (FDA) require pharmaceutical manufacturers to demonstrate that container closure systems are safe, compatible, and suitable for their intended use under current Good Manufacturing Practices (cGMP). USP standards ae recognized by the FDA as official compendial requirements . As a result, companies must either: Comply with USP <661.2>, or Demonstrate an equivalent scientifically justified approach In regulatory submissions such as NDAs, ANDAs, and BLAs , packaging systems are expected to be supported by extractables, leachables, and physicochemical testing consistent with USP <661.2> requirements. Because of this, USP <661.2> testing has effectively become as regulatory expectation for pharmaceutical companies developing or manufacturing drug products using plastic packaging systems. Why This Standard Matters Packaging is often overlooked in pharmaceutical quality discussions, but it plays a critical role in maintaining product integrity. Plastic packaging components can potentially release chemicals into the drug product through processes such as leaching or migration . USP <661.2> addresses this risk by requiring scientific evaluation of packaging systems to ensure they do not introduce contaminants or alter drug stability. These requirements help manufacturers demonstrate: Chemical compatibility between packaging and drug products Control of extractables and leachables Biological safety of packaging materials Overall suitability of the container closure system Ultimately, these tests protect patients by ensuring that packaging does not compromise drug safety or efficacy. Required Testing Under USP <661.2> To comply with USP <661.2>, pharmaceutical companies typically perform a combination of physicochemical, biological, and extractable studies. Examples of tests include: Physicochemical Tests UV absorbance Acidity/alkalinity Total Organic Carbon (TOC) Solution appearance Transmittance and polymer identification markers Extractables & Leachables Studies Identification of compounds that may migrate from packaging into the drug product Quantification of potential contaminants Biological Reactivity Testing In vitro biological tests to confirm the packaging does not cause harmful biological responses. Regulatory Timeline The revised USP chapters USP <661.1> and <661.2> became official on December 1, 2025 , replacing the older USP <661> standard. These new chapters require separate evaluation of packaging materials and packaging systems to demonstrate suitability for pharmaceutical use. This means pharmaceutical companies must ensure their packaging qualification strategies include both material-level testing and full packaging system evaluation. When Testing Is Required USP <661.2> testing is typically required when: Introducing new packaging systems for drug products Making changes to packaging materials or components Launching new drug formulations or dosage forms Responding to regulatory requests during submissions or inspections In Conclusion: USP <661.2> represents a significant step forward in ensuring the safety of pharmaceutical packaging systems. With FDA expectations aligned with USP compendial standards , pharmaceutical companies must take a proactive approach to packaging qualifications. In today's regulatory landscape, testing plastic packaging systems under USP <661.2> is no longer optional—it is a critical component of regulatory compliance and patient safety. If you have any questions regarding your required regulations, call Bird Dog Laboratories at 717-615-9022 or email info@birddoglaboratories.com .

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Do You Understand USP <661.2> and Why It's Crucial for Packaging in the Pharmaceutical Industry?

Ensure your container-closure system offers maximum protection. Bird Dog Labs provides accredited moisture, torque, and USP testing for pharma packaging.

Why is USP <661.2> So Crucial for Packaging in the Pharmaceutical Industry?

Moisture vapor transmission rate (MVTR) testing is crucial for textiles, packaging, and construction industries, especially moisture-sensitive materials. Here are the top five reasons for conducting MVTR testing: 1. Product Quality Assurance: MVTR testing helps ensure that products prone to damage from moisture, such as pharmaceuticals and food packaging, maintain their quality during storage and transportation. 2. Material Selection: MVTR testing aids in selecting the most appropriate packaging materials or product barriers by assessing their resistance to moisture permeation. It ensures that the chosen materials provide adequate protection against moisture ingress. 3. Regulatory Compliance: In many industries, such as pharmaceuticals and food packaging, stringent regulatory requirements regarding moisture protection are in place. MVTR testing is a powerful tool that helps these industries not just meet, but exceed, regulatory standards, ensuring full compliance with relevant regulations. 4. Extended Shelf Life: Controlling moisture transmission is critical for extending the shelf life of perishable products. By determining the MVTR of packaging materials, manufacturers can design packaging that effectively prevents moisture ingress, thereby prolonging the shelf life of products. 5. Cost Reduction: The practical benefits of understanding the MVTR of packaging materials are not to be underestimated. It can lead to substantial cost savings by optimizing material usage. By selecting materials with appropriate moisture barrier properties, manufacturers can significantly reduce the risk of product spoilage or damage, thereby minimizing losses associated with returns or wastage. MVTR testing is not just good practice; it’s essential for maintaining product quality, meeting regulatory standards, extending shelf life, and optimizing costs in industries where moisture control is critical. Contact Abby Korman, Director of Laboratory Development, at akorman@birddoglaboratories.com to learn more about MVTR testing services at Bird Dog Laboratories.

Moisture Vapor Transmission Rate (MVTR) testing is a crucial process that ensures a product’s quality and durability remain intact, even when exposed to various environmental factors. This test is particularly significant in industries such as textiles, packaging, and construction, where the performance of materials under different conditions is paramount. USP 671 is a test that measures the rate at which water passes through material. It ensures materials perform as expected in various environmental conditions. The better the MVTR of a barrier material, the better it prevents moisture ingress. Bird Dog Laboratories, with its team of experienced technicians and specialized equipment, is well-equipped to handle the complex MVTR testing process, instilling confidence in the accuracy and reliability of the results. MVTR Testing results are not just crucial for understanding material behavior in different environmental conditions, but also for ensuring product quality and durability. This testing is valuable at every stage of the design process, from the Unit/Pilot Phase to the finalized production tooling, and even when there are functional changes within the package. Once the testing is complete, Bird Dog Laboratories will prepare a report of the findings and a package classification. The experts at Bird Dog Laboratories are here to help ensure your packaging is ready to take your product to market successfully. Contact Abby Korman, Director of Laboratory Development at akorman@birddoglaboratories.com to learn more about our testing capabilities.